BMT Aerospace’s Smart Factory Revolution: Connecting Machines for a Greener Future
At BMT Aerospace, we're not just keeping up with the times; we're leading the charge into the future with our IIOT-connected-MES project. Imagine a factory where every machine is interconnected, sharing data in real-time to optimize operations. This is the essence of our project. We're embarking on a journey through the six phases of Industry 4.0, aiming to create a fully autonomous manufacturing environment.
Why are We Undertaking This Project?
Continuous improvement
Our primary goal is to boost product quality and operational intelligence. By connecting machines and systems through a centralized network, we can gather and analyze real-time data to predict maintenance needs, minimize downtime, and extend equipment lifespan. This proactive approach enhances our ability to make data-driven decisions, leading to higher standards of productivity and quality.
A more sustainable approach
Plus, we're also committed to sustainability. we reduce waste and energy consumption, aligning with global efforts to combat climate change. As machinery operates more efficiently and with less frequent interruptions. Additionally, smart sensors monitor energy usage across the factory floor, allowing for dynamic adjustments that conserve power during low-demand periods. This interconnected ecosystem supports a sustainable manufacturing process that aligns with global efforts to combat climate change
But how?
An ambitious project like this isn’t set up in a week. That is why in order to reach our goals, we’re working in phases.
- Computerization: Enhancing repetitive tasks with isolated technologies.
- Connectivity: Integrating previously isolated information technologies.
- Visibility: Using sensors to collect real-time data across various operations.
- Transparency: Analyzing data to understand the root causes of issues.
- Predictive Capacity: Creating models to predict future scenarios and reduce unexpected events.
- Adaptability: Enabling the factory to make autonomous decisions based on real-time data.
As a part of the first phases, we’re currently prioritizing two main objectives:
- Building a Manufacturing Execution System (MES): Using the SAP API, we'll create a copy of relevant planning data in the SQL database of the IIOT hub. Operators can report job completions, which are then communicated back to SAP.
- Creating Machine Activity Visibility: By using different sensors to measure power, vibrations, … , we'll visualize machine uptime on a dashboard, comparing planned data with actual working hours and measured machine activity.
Implementation at BMT Aerospace
Our implementation strategy focuses on collecting critical information from three primary sources within the shop floor environment: operators, machines, and sensors. These three sources each have their own unique point of view and data to share. The Manufacturing Execution System (MES) back-end operates on a central gateway while edge devices installed locally gather and pre-process this data. This architecture optimizes data collection processes by minimizing transfers and reducing delay.
Data Storage and Analysis Framework
To effectively store and analyze data, our Industrial Internet of Things (IIOT) platform incorporates a combination of MQTT brokers (servers that manage communication between clients in a publish-subscribe messaging model), historian databases, and relational databases. This robust setup empowers us to monitor machine statuses accurately, predict potential faults proactively, and optimize operations using both real-time insights as well as historical trends.
The Power of Digital Twin Technology
In addition, we are also developing a digital twin—a virtual replica mirroring our physical systems' behaviors. This cutting-edge tool allows us to simulate scenarios, test various changes in manufacturing processes before actual implementation, predict outcomes accurately—and ultimately make informed decisions that enhance productivity while optimizing efficiencies across operations.
A smarter future
The IIOT-connected-MES project is a crucial part of BMT Aerospace's journey towards becoming a smart factory. By connecting our machines and leveraging advanced data analysis, we aim to enhance our manufacturing processes, reduce energy consumption, and improve product quality.